I Like….

Monday
 FERROS METALLURGY
Proses Pembuatan Besi -
Baja
&
Aplikasi Produk Besi-Baja

Mechanical Engineering ITS

 Outline
• Overview
• Sistem produksi besi kasar (pig iron)
• Pembuatan besi - baja ( industry
pembuatan besi -baja)
• Karakterisasi besi-baja –produk besi baja
• Contoh penggunaan- pertimbangan
desain
 Proses
Bijih – besi kasar Besi–baja
 Blast furnace- pig iron  Konverter
 Direct Reduction- spons  Konvertor Bassemer
 Basa
Iron that is produced by reducing iron ore in a
shaft furnace using a mixture of hydrogen and  Asam
carbon monoxide gases. The furnace temperature

.
is not high enough in this process to melt the iron
 Open heart furnace-
oxigen proses
 Electric furnace
 Elctric arc furnace
 Electric induction furnace
• Refractory firebricks –
sampai 2000 o C
• Udara hembus nya – 1000
oC

• Tingginya kira –kira 30 m

• Kapasitas produksi
• 60.000 tons /week
• Atau kebutuhan besi untuk 5
mobil /menit
• Bijih Besi (iron ore)
– Hematit (Fe2O3)
– Limonit (Fe2O3)
– Magnetit (Fe3O4)
– Siderit (Fe3CO4)
Kadungan besi sekitar 50-70
%
• Coke
Batu bara yang di oven
18-24 jam sehingga
mengandung 90-93 % C
• Fluks ( limestones)
Mengikat kotoran menjadi
terak (slag)
calcium limestone,
dolomitic limestone
 Chemical reactions
1) 3 Fe2O3 + CO = CO2 + 2 Fe3O4 Begins at 850° F
2) Fe3O4 + CO = CO2 + 3 FeO Begins at 1100° F
3) 3) FeO + CO = CO2 + Fe
or
FeO + C = CO + Fe Begins at 1300o F

C + O2 = CO2 + Heat
CO2+ C = 2CO
CaCO3 = CaO + CO2
FeS + CaO + C = CaS + FeO + CO

The CaS becomes part of the slag.

The slag is also formed from any remaining Silica (SiO2), Alumina
(Al2O3), Magnesia (MgO) or Calcia (CaO)
 Pig iron
• Iron (Fe) = 93.5 - 95.0%
• Silicon (Si) = 0.30 - 0.90%
• Sulfur (S) = 0.025 - 0.050%
• Manganese (Mn) = 0.55 - 0.75%
• Phosphorus (P) = 0.03 - 0.09%
• Titanium (Ti) = 0.02 - 0.06%
• Carbon (C) = 4.1 - 4.4%
Bassemer konverter

http://en.wikipedia.org/wiki/Image:Bessemer_Converter_Sheffield.jpg
Basics Oxigen Furnace
Basics Oxigen Furnace Step
Electric Arc Furnace
(EAF)
Besi Baja dalam engineering
 Klasifikasi Besi-baja
Besi (cast iron) Kadar C lebih dari 2 %
Baja (steel) Kadar C kurang dari 2 %

• Komposisi kimia; baja karbon, baja paduan,

stainless steel
• Manufacturing methode; OHF, BOF, EAF.
• Finishing methode; Hot or cold rolling
• The produk form; bar, plate, sheet
• The microstructure; ferrite,
pearlite,martensitik.
Struktur mikro
Karena perlakuan
Panas
 Besi Tuang (cast iron)

• Klasifikasi tergantung dari bentuk grafik (C

yang berkumpul) , atau karbida yang terbentuk,
dan struktur mikro dominan
• Tergantung; komposisi kimia, Laju pendinginan,
dan perlakuan panas.
• Macamnya;
• White Irons
• Malleable Irons
• Gray Irons
• Ductile Irons
• Compacted Graphite Irons
 White cast iron
• Terbentuknya eutectic
carbide pada saat
pendinginan
• Mikrostruktur terbentuk
karena pendinginan yang
cepat dan faktor paduan
• sifat ;
– Keuletan rendah
– Kekerasan tinggi
– Baik ketahanan aus (wear)
 Malleable cast iron
• Malleable cast irons are
formed by annealing white
irons to transform the eutectic
cementite to graphite.
• Malleable irons have good
ductility and good strength.
• Matrix microstructure is
dependent upon the cooling
rate from the graphitization
annealing.
• Before the discovery of nodular
irons, malleable irons were the
only ductile class of cast irons.
 Gray cast iron
• Gray cast irons form graphite
flakes during solidification.
• The gray iron microstructure is
due to slow solidification rates
and silicon alloying that
promotes graphite formation.
• Gray irons typically have low
ductility and moderate
strength,
• but they have high thermal
conductivity and excellent
vibration damping properties
 Nodular Cast Iron
• Bentuk grafit nodular
• Pendinginan yang
lambat dengan
penambahan
magnesium dan
serium
Sifat mekanik hasil uji tarik berbagai Mechanical Properties of
besi tuang
Gray Cast Irons
• Gray cast irons exhibit
very little ductility. Typical
elongations in tensile
testing are less than
0.5%.
• Impact strength and
notch sensitivity are poor
due to the graphite flakes
acting as stress risers.
• Fatigue strengths of gray
cast irons are low due to
effects of the graphite
flakes on crack initiation.